American Expedition Vehicles AEV-Nth JK Suspension Systems - Manual (Page 2)

IJKS0100R (JK RHD Suspensions).doc Released: 12-Jan-10 page 2 of 14
Kit Part Numbers 2-dr: Nth02325 3.5” Std., Nth02326 3.5” Premium
4-dr: Nth02345 3.5” Std., Nth02346 3.5” Premium, Nth02446 4.5” Premium
Vehicle Applications ’07-current Jeep JK Wrangler and Unlimited all trim levels including Rubicon
Stock JK frame and axles with all stock brackets intact
Stock Exhaust - or equivalent position for clearance both where it crosses below
the front driveshaft and over the rear track bar.
Stock Front and Rear Driveshafts: Note1: aftermarket units with double-Cardan
joints will require a rear axle pinion angle adjustment that is not provided in
these systems. Note2: A small-diameter front driveshaft is recommended for
clearance on 4.5” systems and all vehicles with automatic transmissions. Assumptions
Equipment that must
already be present on
your Wrangler
Aftermarket Wheels – these are recommended both for adequate width to
mount large tires and decreased backspacing for chassis & steering clearance.
NOTE: JK X-model factory 16-inch wheels will not clear the new drag-link
included in all Premium Suspension Systems. Any AEV JK wheel will solve the
clearance issue or a set of 1.0" thick wheel spacers with your stock wheels.
NOTE2: Wheels with extremely negative offset may negatively affect ESP
(stability control) function.
7/8” drill bit for metal & high-torque drill motor
Floor jack and two jack stands (or vehicle lift with tall jackstands)
Metal cutting tools (several options – see step 9)
Required Tools and
Equipment (in
addition to common
hand tools)
Torque Wrench (ft-lbs)
Install Time (est.) Home/DIY/Shop 1 st install: 10-12 man-hrs; Shop 2 nd or later install: 7-8 man-hrs
Please take the time to read these instructions – they are long because we want you to get the
installation right the first time and enjoy the product immediately thereafter! Do not start or attempt this
product installation if you are unsure of your abilities or do not have the resources listed above. Be sure
to check/set all specified torques with a torque wrench…too tight is not just right!!
Step 1: Unpack boxes Check contents against packing list; Verify parts are in good condition.
Step 2: Read all of the following instruction steps before beginning. Do not disassemble vehicle unless
all parts are present and all tools and facilities required are available.
FRONT SUSPENSION
Step 3: Remove Stock Parts. Place the front portion of the frame on jackstands or use a vehicle lift that
supports the frame directly. Also support the front axle with a floor jack or jack stands, then lower the
axle or raise the Jeep/frame and remove the following parts:
• front
wheels/tires
• springs
• shocks
• front stabilizer end links
1
Notes:
• steering drag link (coupler to knuckle
portion only)
• steering
damper
NOTE: Be sure to save all removed hardware and keep it associated with the location on the Jeep
where it came from – nearly all of it will be reused.